Bidirectional Roller and Print Carriage for Binder Jetting
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Solution Overview
Problem
The binder jetting additive manufacturing technique faces challenges in achieving consistent and rapid layer-by-layer distribution of powder and liquid binder, which affects the quality and commercial viability of formed parts.
Innovation Solution
The implementation of a system with a roller and print carriage that are bidirectionally movable relative to each other, allowing for adjustable spacing and orientation, along with a z-stage actuator to control the position of the roller and print carriage, facilitating consistent layer characteristics and rapid fabrication.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If consistent layer-by-layer distribution of powder and liquid binder is achieved, then manufacturing precision is improved, but productivity deteriorates due to increased time consumption
Solution Approach 1:
The system dynamically switches the relative positioning of the roller and print carriage between forward and reverse directions, allowing both components to move bidirectionally along the build platform. This dynamic repositioning enables the roller to consistently precede the print carriage in both directions, maintaining optimal powder spreading conditions for consistent layer distribution while reducing total traversal time and improving productivity
Solution Approach 2:
The system changes the operational parameters by reversing the direction of movement of the roller and/or print carriage after completing a layer in one direction. This parameter change allows the process to repeat with improved efficiency, as the roller can precede the print carriage in both forward and reverse directions, maintaining manufacturing precision while reducing overall fabrication time
2Manufacturing precision
If the roller is positioned in advance of the print carriage in bidirectional movement, then manufacturing precision is improved through consistent layer characteristics, but device complexity increases due to additional positioning control mechanisms
Solution Approach 1:
The system uses dynamic repositioning of the roller and print carriage through bidirectional movement along the build platform. By reversing directions and maintaining the roller's forward position relative to the print carriage in both directions, the system achieves consistent layer characteristics without requiring complex additional positioning mechanisms beyond the bidirectional movement capability
Solution Approach 2:
The bidirectional movement mechanism serves multiple functions: it enables the roller to precede the print carriage in both forward and reverse directions, facilitates consistent powder spreading across the entire build platform, and allows for efficient traversal patterns that reduce total fabrication time. This multi-functional approach avoids the need for separate positioning systems for each direction
Data Source
AI summary
The devices, systems, and methods of the present disclosure are directed to spreader positioning techniques for consistent and rapid layer-by-layer fabrication of three-dimensional objects formed through binder jetting. For example, an additive manufacturing system may include a roller and a print carriage. In a layer-by-layer fabrication process, the roller may move in advance of the print carriage over a dimension of a volume to spread a respective layer of powder onto which the print carriage delivers a binder. Controlling the position of the roller may facilitate achieving consistent layer characteristics which, in turn, may facilitate fabrication of high quality parts.